EP3542926A1 - Verfahren und vorrichtung zur generativen fertigung mit pulvermaterial - Google Patents

Verfahren und vorrichtung zur generativen fertigung mit pulvermaterial Download PDF

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Publication number
EP3542926A1
EP3542926A1 EP19172027.5A EP19172027A EP3542926A1 EP 3542926 A1 EP3542926 A1 EP 3542926A1 EP 19172027 A EP19172027 A EP 19172027A EP 3542926 A1 EP3542926 A1 EP 3542926A1
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EP
European Patent Office
Prior art keywords
powder
layer
building
tray
powder material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP19172027.5A
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English (en)
French (fr)
Other versions
EP3542926B1 (de
Inventor
Yehoshua Sheinman
Shai Hirsch
Almog SHAHAR
Uri Grach
Kirill TANHILEVICH
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Stratasys Ltd
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Stratasys Ltd
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Publication of EP3542926A1 publication Critical patent/EP3542926A1/de
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Publication of EP3542926B1 publication Critical patent/EP3542926B1/de
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02—Compacting only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10—Formation of a green body
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10—Formation of a green body
    • B22F10/12—Formation of a green body by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10—Formation of a green body
    • B22F10/14—Formation of a green body by jetting of binder onto a bed of metal powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/60—Treatment of workpieces or articles after build-up
    • B22F10/64—Treatment of workpieces or articles after build-up by thermal means
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/70—Recycling
    • B22F10/73—Recycling of powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/58—Means for feeding of material, e.g. heads for changing the material composition, e.g. by mixing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/60—Planarisation devices; Compression devices
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/80—Plants, production lines or modules
    • B22F12/82—Combination of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/86—Serial processing with multiple devices grouped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/003—Apparatus, e.g. furnaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02—Compacting only
    • B22F3/03—Press-moulding apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/205—Means for applying layers
    • B29C64/218—Rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/357—Recycling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0408—Light metal alloys
    • C22C1/0416—Aluminium-based alloys
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    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
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    • B29K2505/00—Use of metals, their alloys or their compounds, as filler
    • B29K2505/02—Aluminium
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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    • Y02P10/25—Process efficiency

Definitions

  • a number of different processes for fabricating solid objects by 3D printing with successive layers of powdered material are known. Some known 3D printing techniques selectively apply a liquid binder material based on a 3D model of the object, binding the material together layer by layer to create a solid structure. In some processes, the object is heated and/or sintered to further strengthen bonding of the material at the end of the building process.
  • Selective Laser Sintering uses a laser as the power source to sinter layers of powdered material.
  • the laser is controlled to aim at points in space defined by a 3D model, binding the material together layer by layer to create a solid structure.
  • Selective laser melting is comparable technique that applies full melting of the material instead of sintering. SLM is typically applied when the melting temperature of the powder is uniform, e.g. when pure metal powders are used as the building material.
  • the apparatus includes a computer controlling a laser to direct the laser energy onto the powder to produce a sintered mass. For each cross-section, the aim of the laser beam is scanned over a layer of powder and the beam is switched on to sinter only the powder within the boundaries of the cross-section. Powder is applied and successive layers sintered until a completed part is formed.
  • the powder comprises a plurality of materials having different dissociation or bonding temperatures.
  • the powder preferably comprises blended or coated materials.
  • a system and method for 3D printing with powder layers may be applied for forming a metal object with powdered metal as the building material.
  • other powdered materials such as plastics and ceramics may be used.
  • a mask for each layer is first printed with a three dimensional printer that deposits solidifiable material, e.g. a photopolymer material or a phase-change ink (e.g., thermal ink) and then a layer is formed by spreading a powder layer over the mask.
  • the mask traces a pattern of solidifiable material.
  • the object being formed from a plurality of layers is defined by the mask pattern that outlines a contour of the object with the solidifiable material and separates the object from the surrounding area, e.g. the support area.
  • a system for building a three dimensional green compact comprising: a printing station configured to print a mask pattern on a building surface, wherein the mask pattern is formed with a solidifiable material; a powder delivery station configured to apply a layer of powder material on the mask pattern; a die compaction station for compacting the layer of powder material and the mask pattern; and a stage configured to repeatedly advance a building tray to each of the printing station, the powder delivery station and the die compaction station to build a plurality of layers that together form the three dimensional green compact.
  • the three dimensional green compact includes an object being formed and a support region.
  • the solidifiable material is selected from the group consisting of a phase-change ink, a thermal ink, a photopolymer material, wax, or any combination thereof.
  • the phase-change ink is a configured to substantially evaporate at a temperature of above 300°C.
  • the powder material is an aluminum alloy.
  • the powder delivery station comprises a powder dispensing station and a powder spreading station.
  • the powder delivery station comprises: a powder hopper configured to store the powder material; a dispensing tip configured to dispense the powder material; a powder dispensing tray configured to receive the powder material from the dispensing tip; and an actuator configured to deliver the powder material on the powder dispensing tray to the building tray.
  • the actuator is configured to simultaneously open a longitudinal aperture located at the bottom of each of the plurality of troughs.
  • the hopper includes an auger through which the powder material is controllably advanced into the dispensing tip.
  • the powder delivery station includes a roller and wherein the roller is actuated to both rotate and move across the layer for spreading the powder material.
  • the roller is a forward roller.
  • the powder delivery station includes a plurality of gutters configured to receive excess powder material falling from the edges of the building tray during roller movement across the layer for spreading the powder material.
  • the plurality of gutters includes a first pair of gutters that are actuated to move together with the roller during the spreading of the powder material.
  • the first pair of gutters is located below the lateral ends of the roller.
  • each of the gutters of the first pair of gutters has a length of at least twice the diameter of the roller and is extending on both sides of the roller lateral ends.
  • the powder accumulated in said first pair of gutters is continuously removed from the gutter internal space during the spreading of the powder material via an air suction.
  • the air suction is applied in the second pair of gutters when the air suction applied in the first pair of gutters is switched off.
  • the powder delivery station is configured to recirculate the excess powder material to the powder hopper.
  • the powder delivery station includes at least one cyclone separator configured to remove air from the powder material collected from the plurality of gutters.
  • the powder delivery station includes a plurality of cyclone separators operated in series.
  • the at least one cyclone separator includes a cap configured to seal an outlet during operation of the cyclone separator.
  • the powder delivery station includes a mesh configured to separate the powder material from debris prior to delivering the powder material to the powder hopper.
  • the die compaction station includes side walls that are configured to be introduced around the building tray.
  • the side walls are configured to be introduced around the building tray based on contact of the layer with the compacting station.
  • a system for forming a three dimensional object comprising: a system for building a three dimensional green compact as described above; and a post-processing station selected from the group consisting of a second compacting station, a heating station, a sintering station, and any combination thereof.
  • a method for building a three dimensional green compact comprising: printing a mask pattern on a building surface with solidifiable material; forming a layer by spreading powder material on the mask pattern; compacting the layer; and repeating the printing, forming and compacting until the three dimensional green compact is completed.
  • the three dimensional green compact includes an object being formed and a supporting region.
  • spreading powder material comprises dispensing a plurality of rows of powder material on the building surface and spreading the plurality of rows of powder material with a roller.
  • the plurality of rows of powder material is prepared off-line prior to dispensing on the building tray.
  • the plurality of rows of powder material is positioned perpendicular to a spreading direction.
  • the spreading includes rolling a roller over the powder material.
  • the spreading direction is inverted from one powder layer to the subsequent one.
  • the positioning of the plurality of rows of powder varies from one powder layer to the subsequent one.
  • the method includes collecting excess powder material from the building surface based on the spreading and recirculating the excess powder material to a powder hopper.
  • the collecting and the recirculating are performed online.
  • the method includes suctioning the excess powder to at least one cyclone separator and separating the powder from air in the at least one cyclone separator.
  • the method includes operating a plurality of cyclone separators in series.
  • the method includes filtering the powder material from the at least one cyclone separator with a mesh and delivering powder material filtered through the mesh to a powder hopper, wherein the powder hopper provides the powder material for building the three dimensional green compact.
  • the compacting is die compaction.
  • the mask pattern includes a contour of the green compact per layer.
  • the printing, forming and compacting are performed in ambient temperatures.
  • a first layer is formed on a building tray coated with a tacky material.
  • a method for forming a three dimensional object comprising: building a three dimensional green compact according to the method described above, wherein said three dimensional green compact comprises an object and a support region including solidifiable material; and post-processing the green compact by removing the solidifiable material; separating the object from the support region; and sintering the object.
  • removing the solidifiable material and separating the object from the support region is performed before sintering.
  • removing the solidifiable material is performed during sintering.
  • post-processing further comprises compacting the green compact as a whole.
  • the thermal ink has a melt temperature of between 55-65 °C and a working temperature of about 65-75°C, the viscosity may be between 15-17cPs. According to embodiments of the present invention, the thermal ink is configured to evaporate in response to heating with little or no carbon traces.
  • Building with aluminum is known to be advantageous due to its light weight, heat and electricity conduction, and its relative resistance to corrosion.
  • the melting temperature of aluminum is relatively low.
  • One of the challenges of building with aluminum powder is that the aluminum particles of the powder tend to form an aluminum oxide coating, e.g. alumina.
  • the aluminum oxide coating introduces a barrier between the aluminum particles that interferes with bonding of the particles during sintering.
  • the final result is typically an object with reduced strength due to poor bonding between the powdered elements.
  • one or more stations along a path of precision stage 250 are supported on rails extending along the path and/or by one or more bridges, e.g. bridge positioned over working platform 500.
  • compacting station 40 includes a piston 42 positioned below working platform 500 that is operated to raise tray 200 with rod 42A toward a flattening surface 45 positioned above tray 200 or other surface as is described in further detail herein below.
  • the method includes printing a mask pattern per layer that defines a boundary of an object or green body being formed and also extensions that later facilitate separating the object from surrounding material (block 305).
  • the method further includes dispensing powder layer on a building tray (block 310) and spreading the powder layer over the mask pattern to obtain a uniform layer of powder (block 320).
  • the powder is aluminum.
  • other metals or alternatively ceramic material is used as the building material, e.g. the powder.
  • the powder is a mix of a plurality of materials.
  • FIG. 12 showing a simplified flow chart of an exemplary method for forming an object based on 3D printing in accordance with some embodiments of the present invention.
  • the built layers forming a green compact are removed from the automated stage (block 405) and compacted again at optionally a higher pressure, temperature and/or longer duration (block 410).
  • the final compaction of the whole green body is performed at a pressure of between 150-300 MPa, in aluminum case e.g. 250 MPa or a temperature below 430°C.
  • the layers are compacted for an extended duration of time, e.g. 2-6 minutes.
  • the compaction is die compaction so that only the Z-axis is compacted during the process.
  • sintering is typically applied (block 415).
  • sintering is applied in a plurality of stages.
  • the built layers are heated at relatively low temperature, e.g. below 400°C over a first duration, e.g. 20-180 minutes.
  • this step may require an inert environment of Nitrogen.
  • the mask pattern is burned at this stage, mainly due to the oxygen contained in the polymer.
  • the temperature may be raised, e.g.
  • An aspect of some exemplary embodiments of the present invention provides for a system for building a three dimensional object comprising: a digital printing station configured to print a mask on a building surface, wherein the mask is formed from at least one of photopolymer material and wax material that is configured to burn during sintering; a powder delivery station configured to apply a layer of powder material on the mask pattern; a process compaction station for compacting per layer of powder material, wherein the compaction station includes a die for receiving the layer; a stage configured to repeatedly advancing the building tray to each of the digital printing station, the powder delivery station and the process compaction station to build a plurality of layers that together form the three dimensional object; and a sintering station configured to sinter the plurality of layers.
  • the process compacting station includes side walls that are configured to be introduced around the building tray based on contact of the layer with the compacting station.
  • the side walls are locked in place such that they have minimal movement, e.g. less than 0.1mm under the reaction forces developed in the powder block while compacting.
  • the system includes a final compaction station configured to compact the plurality of layers.
  • the final compaction station heat compacts the plurality of layers over a plurality of heating stages.
  • the powder delivery station includes a motorized roller that is configured to move across the layer for spreading the powder.
  • An aspect of some exemplary embodiments of the present invention provides for a method for building a three dimensional object comprising: printing a mask on a building surface, wherein the mask is formed from at least one of a photopolymer material and wax that is configured to burn during sintering; spreading a layer of powder on the mask pattern; compacting the layer of powder; repeating the printing, spreading and compacting until layers of the three dimensional object is completed; and sintering the layers of the three dimensional object.
  • the method includes applying heat during the compacting.
  • the mask additionally includes a pattern that extends from the contour of the object per layer toward edges of a footprint of the layer.
  • the method includes milling or grinding the layer after compaction and before printing an additional mask on the layer.
  • powder 51 is spread over the mask pattern 510 and across a footprint of a building tray 200.
  • powder 51 is spread with a roller 25.
  • roller 25 is actuated to both rotate about its axle 24 and to move across building tray 200 along an X axis.
  • compaction 520 may be applied on the entire layer to compact layer 506.
  • a height of layer 506 is reduced due to process compaction.
  • an object i.e. a green body
  • a cyclic process may include the steps of printing a mask pattern (block 530) at a printing station 535, dispensing and spreading a powder material (block 540) over the mask at a dispensing and spreading station 545 (also referred to as "powder delivery station") and compacting the powder layer including the mask pattern (block 550) at a compacting station 555.
  • this cyclic process yields a green compact or green block.
  • the green compact may include one or more objects (i.e. green bodies) surrounded by mask and building material forming support regions outside of the object.
  • both the object(s) and the surrounding support regions including the mask make up a green compact formed with the powder material that was dispensed and spread during the cyclic process.
  • the mask pattern that was printed defines a boundary around the object(s) and optionally regions within the block that enables extracting the object(s) from the surrounding material.
  • the object(s) once extracted from the surrounding material may be further post processed, e.g. may be further compacted over one or more steps prior to sintering.
  • a powder dispenser 600 dispenses a plurality of rows of powder material per layer.
  • the rows of powder dispensed by powder dispenser 600 are spread off-line on a dedicated spreading tray 670 including a plurality of troughs 660 in which powder 51 is received.
  • powder dispenser 600 includes a first rail 610 that advances the troughs below the hopper 640 so that the hopper may dispense powder into each of the plurality of troughs 660 of the powder dispensing tray in turn, and a second rail 620 that moves the powder dispensing tray below the hopper such that the hopper 640 dispenses powder 51 through a dispensing tip 650 along each of the plurality of troughs 660 until all the troughs have been filled.
  • movement along each of first rail 610 and second rail 620 is actuated with a dedicated motor.
  • powder hopper 640 includes an auger for precise powder dosing per row, e.g. per trough 660.
  • powder dispenser 600 includes a piston 630 that actuates transferring the rows of powder material from spreading tray 670 to the building tray 200 ( FIG. 15 ) once all the rows have been prepared.
  • piston 630 is configured to simultaneously flip each of the troughs 660 of spreading tray 670 onto building tray 200.
  • each of the troughs 660 includes a longitudinal aperture along the base of the trough that is covered or closed and piston 630 is configured to actuate simultaneously opening the longitudinal apertures to dispense rows of powder material onto building tray 200.
  • the rows are positioned on the building tray so that they are parallel with a roller 25 ( FIG. 13 ), e.g. parallel with axle 24 of rotation of roller 25 and perpendicular to linear movement of roller 25 across the building tray, e.g. perpendicular to the X axis ( FIG. 13 ).
  • a roller 25 FIG. 13
  • axle 24 of rotation of roller 25 e.g. parallel with axle 24 of rotation of roller 25
  • perpendicular to linear movement of roller 25 across the building tray e.g. perpendicular to the X axis ( FIG. 13 ).
  • 2-20 rows of powder are spread on spreading tray 670 per layer.
  • roller 25 spreads the rows of powder 51 across building tray 200.
  • a spreading unit 700 includes a roller 25, a pair of side gutters 730 and a pair of end gutters 740.
  • Side gutters 730 and end gutters 740 are configured to collect excess powder 51 on building tray 200 as roller 25 is rolled across building tray 200.
  • roller 25 is actuated to move along a rail 710 across building tray 200 along the X axis ( FIG. 13 ) and is also actuated with a motor 720 to rotate about its axle 24.
  • motor 720 travels on rail 710 and rotates roller 25 as it moves across building tray 200 along a direction of the X axis.
  • Roller 25 may be actuated to move forward, backwards along a direction of the X axis or both forward and backwards along a direction of the X axis.
  • spreading unit 700 alternates between moving roller 25 in a forward and backward direction.
  • a direction of rotation of roller 25 about its axle24 is adapted to the linear direction of movement of roller 25.
  • each of side gutters 730 is positioned below each end of roller 25 and the pair of side gutters 730 move together with roller 25 along rail 710.
  • Side gutters are configured to collect excess powder 51 that falls off of building tray 200 as roller 25 spreads powder 51.
  • a length of side gutter 730 along a direction of rail 710 is at least twice a diameter of the roller 25.
  • each of end gutters 740 is located near an edge of building tray 200 that is parallel to roller 25 and perpendicular to rail 710 and extends at least along the entire edge of building tray 200 to collect excess powder that falls off building tray 200 as roller 25 spreads powder 51.
  • end gutters 740 are positioned at the level at which roller 25 touches building tray 200 or building surface, e.g. top of uppermost layer. End gutters 740 move together with roller 25 along rail 710 but are also separately actuated to move toward and away from building tray 200 as needed.
  • movement of end gutters 740 toward and away from the building tray 200 is in the order of magnitude of 1 mm to 1 cm.
  • end gutters are configured to move toward building tray 200 to collect the excess powder and to move away from the building tray during movement of the building tray, e.g. vertical or lateral movement of building tray 200.
  • a vacuum (creating an air suction) is applied to remove the powder accumulated in each of the side gutters 730 and end gutters 740 as the roller spreads powder 51 across building tray 200.
  • the vacuum is alternately applied to side gutters 730 and end gutters 740 based on position of roller 25.
  • the vacuum is alternately applied to each of the pair of end gutters 740 based on position of roller 25.
  • between 50%-80% of powder 51 that is dispensed per layer on building tray 200 is collected in side gutters 730 and end gutters 740.
  • the collected powder may be transferred to a recirculation system that reintroduces the collected powder to powder hopper 640.
  • a powder recirculation system 800 includes a container 810 that is configured to receive powder collected from side gutters 730 and end gutters 740 of spreading unit 700, one or more cyclone separators 820 configured to remove air from powder in container 810, a mesh 840 to separate debris from the powder separated by cyclone separators 820 and a spout 860 through which the powder is dispensed into powder hopper 640.
  • cyclone separators 820 are operated in series.
  • the series facilitates collecting powder particles with different sizes and weights at a high efficiency by varying the filtering conditions (e.g. air flow speed, cyclone diameter) from one cyclone separator 820 to another.
  • contents in container 810 may first be introduced into one of cyclone separators 820.
  • Air removed from the first cyclone separator may be introduced into a second one of cyclone separators 820.
  • the air removed from the first cyclone separator may still contain powder material and that material may be separated in the second cyclone separator. This process may be continued for all the cyclone separators.
  • powder is substantially continuously introduced into container 810 during the spreading process and substantially continuously streamed from one cyclone separators to the next so that all the cyclone separators are operated simultaneously.
  • powder recirculation system 800 includes four cyclone separators.
  • the cyclone separators include caps configured to seal an outlet during operation of the cyclone separator.
  • the cap is periodically released to collect the powder from cyclone separators 820.
  • the cap is released between periods of operation of spreading unit 700.
  • a piston 830 controls a simultaneous release of all the caps.
  • powder collected from cyclone separators 820 is filtered through mesh 840 to separate it from any debris or clumped powder that may have been collected.
  • a piston 850 actuates vibration of mesh 840 to facilitate the filtering. The powder filtered through the mesh may then be introduced into the hopper and mixed into the powder in the hopper 640.
  • compositions, method or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.

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